Motorized tensioning system with sensors

ABSTRACT

A tensioning system for articles of footwear and articles of apparel is disclosed. The tensioning system includes a tensioning member that is tightened or loosened using a motorized tensioning device for winding and unwinding the tensioning member on a spool. The tensioning system may be used with various sensors to determine how the motorized tensioning device should be controlled.

RELATED APPLICATION

This application is a division of U.S. application Ser. No. 14/014,555,entitled “Motorized Tensioning System with Sensors”, filed on Aug. 30,2013, which application claims the benefit of priority to U.S.Provisional Patent Application Ser. No. 61/695,953, filed on Aug. 31,2012, both of which are incorporated by reference herein in itsentirety.

BACKGROUND

The present embodiments relate generally to articles of footwear andapparel including tensioning systems.

Articles of footwear generally include two primary elements: an upperand a sole structure. The upper is often formed from a plurality ofmaterial elements (e.g., textiles, polymer sheet layers, foam layers,leather, synthetic leather) that are stitched or adhesively bondedtogether to form a void on the interior of the footwear for comfortablyand securely receiving a foot. More particularly, the upper forms astructure that extends over instep and toe areas of the foot, alongmedial and lateral sides of the foot, and around a heel area of thefoot. The upper may also incorporate a lacing system to adjust the fitof the footwear, as well as permitting entry and removal of the footfrom the void within the upper. Likewise, some articles of apparel mayinclude various kinds of closure systems for adjusting the fit of theapparel.

SUMMARY

In one aspect, a method of operating a motorized tensioning device in anarticle of footwear includes sensing information related to a user settension of a tensioning member used to fasten the article of footwear.The method also includes sensing a current tension of the tensioningmember and determining if the current tension is less than the user settension. The method also includes automatically controlling themotorized tensioning device to increase the tension of the tensioningmember to achieve the user set tension when the current tension is lessthan the user set tension.

In another aspect, an article of footwear includes a tensioning member,a motorized tensioning device for controlling the tension of thetensioning member, at least one sensor for receiving information relatedto the tension of the tensioning member and a control unit, where thecontrol unit can receive information from the at least one sensor. Thecontrol unit operates the motorized tensioning device in a normaloperating mode and an active operating mode. The control unit powersdown the motorized tensioning device after a target tension has beenachieved in the normal operating mode. The control unit monitors thetension of the tensioning member and adjusts the motorized tensioningdevice to maintain the target tension in the active operating mode.

In another aspect, a footwear tension control system includes an articleof footwear including a tensioning member, a motorized tensioning devicefor adjusting tension in the tensioning member, and a user controlsystem in communication with the motorized tensioning device, where theuser control system includes inputs that provide commands to themotorized tensioning device. The user control system includes a footwearselection input, the footwear selection input allowing the user toselect between sending commands to a left article of footwear or a rightarticle of footwear. The user control system includes a tighten input.The user control system includes a loosen input.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic isometric view of an embodiment of an article offootwear with a tensioning system and a remote device for controllingthe tensioning system;

FIG. 2 is a schematic view of an embodiment of a remote device running alacing control application;

FIG. 3 is a schematic view of an embodiment of a foot being insertedinto an article and a remote device running a lacing controlapplication;

FIG. 4 is a schematic view of an embodiment of a foot fully insertedinto an article and a remote device running a lacing controlapplication;

FIG. 5 is a schematic view of an embodiment of an article beingtightened as a remote device sends an incremental tighten command to atensioning system;

FIG. 6 is a schematic view of an embodiment of an article being loosenedas a remote device sends an incremental loosen command to a tensioningsystem;

FIG. 7 is a schematic view of an embodiment of an article opened toallow a foot to be removed after a remote device has sent an opencommand to a tensioning system;

FIG. 8 is a schematic isometric view of an embodiment of a motorizedtensioning device with an outer cover of the housing unit removed;

FIG. 9 is a schematic exploded isometric view of an embodiment of somecomponents of a motorized tensioning device;

FIG. 10 is a schematic exploded isometric view of an embodiment of aratcheting assembly;

FIG. 11 is a schematic isometric view of a portion of a motorizedtensioning system showing a ratcheting assembly clamped to a spool;

FIG. 12 is a schematic isometric view of an embodiment of a shaft and arotational control assembly;

FIG. 13 is a schematic isometric view of a portion of a motorizedtensioning system showing a rotational control assembly engaging aspool;

FIG. 14 is another schematic isometric view of a portion of therotational control assembly of FIG. 13;

FIG. 15 is a schematic isometric view of an embodiment of a spool;

FIG. 16 is a side schematic view of an embodiment of a torquetransmitting system;

FIG. 17 is a side schematic view of an embodiment of a torquetransmitting system in a fully loosened configuration;

FIG. 18 is a side schematic view of an embodiment of a torquetransmitting system in an incremental tightening configuration;

FIG. 19 is a side schematic view of an embodiment of a torquetransmitting system in an incremental tighten configuration;

FIG. 20 is a schematic isometric view of a portion of a torquetransmitting system as a gear contacts a ratcheting assembly;

FIG. 21 is a schematic isometric view of the portion of torquetransmitting system of FIG. 20, in which the gear, ratcheting assemblyand spool are clamped together and the spool is rotated;

FIG. 22 is a side schematic isometric view of a torque transmittingsystem in an incremental loosen configuration;

FIG. 23 is a schematic isometric view of a torque transmitting system ina first stage of an incremental loosen configuration;

FIG. 24 is a schematic isometric view of a torque transmitting system ina second stage of an incremental loosen configuration;

FIG. 25 is a schematic isometric view of a torque transmitting system ina third stage of an incremental loosen configuration;

FIG. 26 is a schematic side view of an embodiment of a torquetransmitting system transitioning to a full loosening configuration;

FIG. 27 is a schematic isometric view of a secondary winding assemblyoperating while a lace is being wound onto a spool;

FIG. 28 is a schematic isometric view of a secondary winding assemblyoperating while a lace is being unwound from a spool due to tension onthe lace;

FIG. 29 is a schematic isometric view of a secondary winding assemblyoperating when a lace has developed some slack near the spool;

FIG. 30 is a schematic isometric view of motorized tensioning deviceincluding an alternative configuration for a secondary winding assembly;

FIG. 31 is a top down schematic view of a portion of an articleincluding an external heel counter, in which the locations of amotorized tensioning device, a control unit and a battery are indicatedschematically;

FIG. 32 is an isometric schematic view of an article of apparelincluding shoulder pads worn by a user;

FIG. 33 is a schematic enlarged view of an embodiment of a padconfigured with a tensioning system;

FIG. 34 is a schematic enlarged view of an embodiment of a padconfigured with a tensioning system in which a cable of the tensioningsystem has been tightened around the pad;

FIG. 35 is a schematic isometric view of an embodiment of a user with anarticle of apparel having a tensioning device and a remote device forcontrolling the tensioning device;

FIG. 36 is a schematic isometric view of the user, apparel and remotedevice of FIG. 35, in which the user has selected an incremental tightenbutton and the motorized tensioning device has increased tension aroundthe pad;

FIG. 37 is a schematic isometric view of an embodiment of additionalarticles of apparel that may be configured with tensioning systemsincluding motorized tensioning devices;

FIG. 38 is a schematic isometric view of an embodiment of an article offootwear including a tensioning system and a remote bracelet configuredto control a motorized tensioning device of the tensioning system;

FIG. 39 is a schematic process for automatically controlling tension inan article to maintain an initial tension;

FIG. 40 is a schematic process for automatically controlling tensionaccording to a user selected tensioning mode;

FIG. 41 is a schematic isometric view of an alternative embodiment of amotorized tensioning device;

FIG. 42 is an enlarged isometric view of a load-holding mechanism of themotorized tensioning device of FIG. 41;

FIG. 43 is a cut-away view of an embodiment of a portion of a motorizedtensioning device;

FIG. 44 is an isometric view of another embodiment of a load holdingmechanism for a motorized tensioning device;

FIG. 45 is an isometric view of the load holding mechanism of FIG. 44,in which an output ring has been removed;

FIG. 46 is a schematic isometric view of an embodiment of a manualrelease mechanism for a tensioning system including a motorizedtensioning device;

FIG. 47 is an isometric view of another embodiment of a load holdingmechanism for a motorized tensioning device;

FIG. 48 illustrates exemplary communication modes between a tighteningsystem and a computer;

FIG. 49 illustrates an exemplary user interface including a dial fortightening or loosening tension;

FIG. 50 illustrates an exemplary remote interface for tightening a kneebrace;

FIG. 51 illustrates an inductive charging configuration for a brace;

FIG. 52 illustrates a user interface for a motorized tightening device,the interface including a conductive panel; and

FIGS. 53-54 illustrate examples of ratcheting mechanisms for differentembodiments of a motorized tensioning device.

DETAILED DESCRIPTION

Overview

FIG. 1 illustrates a schematic isometric view of an embodiment ofarticle of footwear 100 that is configured with a tensioning system 150.In the current embodiment, article of footwear 100, also referred tohereafter simply as article 100, is shown in the form of an athleticshoe, such as a running shoe. However, in other embodiments, tensioningsystem 150 may be used with any other kind of footwear including, butnot limited to: hiking boots, soccer shoes, football shoes, sneakers,running shoes, cross-training shoes, rugby shoes, basketball shoes,baseball shoes as well as other kinds of shoes. Moreover, in someembodiments article 100 may be configured for use with various kinds ofnon-sports related footwear, including, but not limited to: slippers,sandals, high heeled footwear, loafers as well as any other kinds offootwear. As discussed in further detail below, a tensioning system maynot be limited to footwear and in other embodiments a tensioning systemcould be used with various kinds of apparel, including clothing,sportswear, sporting equipment and other kinds of apparel. In stillother embodiments, a tensioning system may be used with braces, such asmedical braces.

Referring to FIG. 1, for purposes of reference, article 100 may bedivided into forefoot portion 10, midfoot portion 12 and heel portion14. Forefoot portion 10 may be generally associated with the toes andjoints connecting the metatarsals with the phalanges. Midfoot portion 12may be generally associated with the arch of a foot. Likewise, heelportion 14 may be generally associated with the heel of a foot,including the calcaneus bone. It will be understood that forefootportion 10, midfoot portion 12 and heel portion 14 are only intended forpurposes of description and are not intended to demarcate preciseregions of article 100.

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “longitudinal” as used throughout this detaileddescription and in the claims refers to a direction extending a lengthof a component. Also, the term “lateral” as used throughout thisdetailed description and in the claims refers to a direction extending awidth of a component. Furthermore, the term “vertical” as usedthroughout this detailed description and in the claims refers to adirection that is perpendicular to both the longitudinal and lateraldirections. It will be understood that each of these directionaladjectives may be applied to various components shown in theembodiments, including article 100, as well as components of tensioningsystem 120.

Article 100 may include upper 102 and sole structure 104. Generally,upper 102 may be any type of upper. In particular, upper 102 may haveany design, shape, size and/or color. For example, in embodiments wherearticle 100 is a basketball shoe, upper 102 could be a high top upperthat is shaped to provide high support on an ankle. In embodiments wherearticle 100 is a running shoe, upper 102 could be a low top upper.

In some embodiments, sole structure 104 may be configured to providetraction for article 100. In addition to providing traction, solestructure 104 may attenuate ground reaction forces when compressedbetween the foot and the ground during walking, running or otherambulatory activities. The configuration of sole structure 104 may varysignificantly in different embodiments to include a variety ofconventional or non-conventional structures. In some cases, theconfiguration of sole structure 104 can be configured according to oneor more types of ground surfaces on which sole structure 104 may beused. Examples of ground surfaces include, but are not limited to:natural turf, synthetic turf, dirt, as well as other surfaces.

In different embodiments, sole structure 104 may include differentcomponents. For example, sole structure 104 may include an outsole, amidsole, and/or an insole. In addition, in some cases, sole structure104 can include one or more cleat members or traction elements that areconfigured to increase traction with a ground surface.

In some embodiments, sole structure 104 may be joined with upper 102. Insome cases, upper 102 is configured to wrap around a foot and securesole structure 104 to the foot. In some cases, upper 102 may includeopening 130 that provides access to an interior cavity of article 100.

A tensioning system may include a tensioning member. The term“tensioning member” as used throughout this detailed description and inthe claims refers to any component that has a generally elongated shapeand high tensile strength. In some cases, a tensioning member could alsohave a generally low elasticity. Examples of different tensioningmembers include, but are not limited to: laces, cables, straps andcords. In some cases, tensioning members may be used to fasten and/ortighten an article, including articles of clothing and/or footwear. Inother cases, tensioning members may be used to apply tension at apredetermined location for purposes of actuating some components orsystem.

Tensioning system 150 may comprise various components and systems foradjusting the size of opening 130 and thereby tightening (or loosening)upper 102 around a wearer's foot. In some embodiments, tensioning system150 may comprise lace 152 as well as motorized tensioning device 160.Lace 152 may be configured to pass through various different lacingguides 154, which may be further associated with the edges of throatopening 132. In some cases, lacing guides 154 may provide a similarfunction to traditional eyelets on uppers. In particular, as lace 152 ispulled or tensioned, throat opening 132 may generally constrict so thatupper 102 is tightened around a foot.

The arrangement of lacing guides 154 in this embodiment is only intendedto be exemplary and it will be understood that other embodiments are notlimited to a particular configuration for lacing guides 154.Furthermore, the particular types of lacing guides 154 illustrated inthe embodiments are also exemplary and other embodiments may incorporateany other kinds of lacing guides or similar lacing provisions. In someother embodiments, for example, lace 154 could be inserted throughtraditional eyelets. Some examples of lace guiding provisions that maybe incorporated into the embodiments are disclosed in Cotterman et al.,U.S. Patent Application Publication Number 2012/0000091, now U.S.application Ser. No. 13/174,527, filed Jun. 30, 2011, and entitled “LaceGuide”, which is hereby incorporated by reference in its entirety.Additional examples are disclosed in Goodman et al., U.S. PatentApplication Publication Number 2011/0266384, now U.S. application Ser.No. 13/098,276, filed Apr. 29, 2011 and entitled “Reel Based LacingSystem” (the “Reel Based Lacing Application”), which is herebyincorporated by reference in its entirety. Still additional examples oflace guides are disclosed in Kerns et al., U.S. Patent ApplicationPublication Number 2011/0225843, now U.S. application Ser. No.13/011,707, filed Jan. 21, 2011 and entitled “Guides For LacingSystems”, which is hereby incorporated by reference in its entirety.

Lace 152 may comprise any type of type of lacing material known in theart. Examples of lace that may be used include cables or fibers having alow modulus of elasticity as well as a high tensile strength. A lace maycomprise a single strand of material, or can comprise multiple strandsof material. An exemplary material for the lace is SPECTRA™,manufactured by Honeywell of Morris Township N.J., although other kindsof extended chain, high modulus polyethylene fiber materials can also beused as a lace. Still further exemplary properties of a lace can befound in the Reel Based Lacing Application mentioned above.

In some embodiments, lace 152 may be passed through lacing guides 154and may pass through internal channels (not shown) within upper 102after entering channel openings 156 that are above lacing guides 156. Insome embodiments, the internal channels extend around the sides of upper102 and guide the lace towards motorized tensioning device 160, whichmay be mounted on heel portion 14 of upper 102. In some cases, motorizedtensioning device 160 may include provisions for receiving portions oflace 152. In some cases, end portions of lace 152 exit internal channelsof upper 102 and pass through apertures in a housing unit 212 ofmotorized tensioning device 160.

Motorized tensioning device 160 may be configured to automatically applytension to lace 152 for purposes of tightening and loosening upper 102.As described in further detail below, motorized tensioning device 160may include provisions for winding lace 152 onto, and unwinding lace 152from, a spool internal to motorized tensioning device 160. Moreover, theprovisions may include an electric motor that automatically winds andunwinds the spool in response to various inputs or controls.

Provisions for mounting motorized tensioning device 160 to upper 102 canvary in different embodiments. In some cases, motorized tensioningdevice 160 may be removably attached, so that motorized tensioningsystem 160 can be easily removed by a user and modified (for example,when a lace must be changed). Examples of provisions for removablyattaching motorized tensioning system 160 to upper 102 are discussed indetail later. In other cases, motorized lacing device 160 could bepermanently attached to upper 102. In one embodiment, for example, anexternal harness (not shown) may be used to mount motorized tensioningsystem 160 to upper 102 at heel portion 14.

In some embodiments, motorized tensioning device 160 may communicatewith remote device 170. In some cases, motorized tensioning device 160may receive operating instructions from remote device 170. For example,motorized tensioning device 160 may receive instructions to applyincreased tension to lace 152 by winding the spool. In some cases,remote device 170 may be capable of receiving information from motorizedtensioning device 160. For example, remote device 170 could receiveinformation related to the current tension in lace 152 and/or othersensed information. As discussed below in reference to FIG. 2, remotedevice 170 may function as a remote control that may be used by thewearer to operate tensioning system 150.

In one embodiment, remote device 170 comprises a mobile phone, such asthe iPhone made by Apple, Inc. In other embodiments, any other kinds ofmobile phones could also be used including smartphones. In otherembodiments, any portable electronic devices could be used including,but not limited to: personal digital assistants, digital music players,tablet computers, laptop computers, ultrabook computers as well as anyother kinds of portable electronic devices. In still other embodiments,any other kinds of remote devices could be used including remote devicesspecifically designed for controlling motorized tensioning device 160.In another embodiment, discussed in detail below, remote device 170could comprise a bracelet, wristband and/or armband that is worn by auser and specifically designed for communicating with motorizedtensioning device 160. The type of remote device could be selectedaccording to software and hardware requirements, ease of mobility,manufacturing expenses, as well as possibly other factors. In someembodiments, motorized tightening device 160 may communicate withmultiple remote devices. For example, a user may use a mobile device,such as an iPhone, at home to identify and set preferred tensionsettings, and another remote device with more rudimentary controls mightthen be used to issue commands to motorized tightening device 160, suchas with a bracelet, wristband and/or armband while playing sports. Forexample, a bracelet might allow a user to recall a set tension andadjust it, but not set a new tension for later recall. In someembodiments, such as where motorized tightening device 160 is used for amedical brace, a physician may be provided with fewer controls for themedical brace. For example, the wearer may be provided with a remotedevice that allows a full range of commands and/or tensions foradjusting fit or performance, but the wearer of that brace may beprovided with a remote device that is not configured to issue all of thecommands available with the physician's remote device and/or allows amore limited range of tension adjustment, such as for improving comfortwithout disturbing the overall fit of the brace.

As already mentioned, remote device 170 may communicate with motorizedtightening device 160 (or indirectly with motorized tightening device160 via a secondary device, such as a separate control unit). Examplesof different communication methods include, but are not limited to:wireless networks such as personal area networks (e.g., Blutetooth) andlocal area networks (e.g., Wi-Fi) as well as any kinds of RF basedmethods known in the art. In some embodiments, infrared light may beused for wireless communication. Although the illustrated embodimentsdetail a remote device 170 that communicates wirelessly with motorizedtensioning system 160, in other embodiments remote device 170 andmotorized tensioning system 160 may be physically connected andcommunicate through one or more wires.

For purposes of clarity, a single article of footwear is shown in theembodiments. However, it will be understood that remote device 170 maybe configured to operate a corresponding article of footwear which alsoincludes a similar tensioning system (e.g., a pair of footwear eachhaving a tensioning system). As described below, remote device 170 maybe used to operate each the tensioning systems of each articleindependently of one another.

FIG. 2 illustrates a schematic view of an embodiment of remote device170, including a schematic of an example user interface for controllingtensioning system 150. In some embodiments, remote device 170 may becapable of running a lacing control software application 180, hereafterreferred to simply as application 180. In embodiments where remotedevice 170 is a mobile phone (or similar digital device) capable ofrunning mobile software applications, application 180 may be downloadedby a user from a third party online store or website. Such a mobilephone (or similar digital device) may include a touch screen LCD devicewhich may be used by application 180 for input and output interactionwith a user. In some embodiments, a touch screen LCD or non-touch screenLCD may be used for output display only.

Application 180 may display and respond to user interaction with aplurality of control buttons 182, and initiate control commands inresponse to such interaction. Example control commands may include, butare not limited to, left/right shoe selection, incremental tighten,incremental loosen, open/fully loosen, store tension, and recall/restoretension. In the exemplary embodiment of FIG. 2, these control buttonsinclude a first button 191 and a second button 192, which arerespectively used to select the left or right shoe that will receive andrespond to the control commands. In some embodiments, either firstbutton 191 or second button 192 may be selected, but both may not beselected simultaneously. In other cases, it may be possible to selectboth first button 191 and second button 192 simultaneously, to allow auser to tighten, loosen, or open both shoes simultaneously. In addition,application 180 may include third button 193 for initiating an“incremental tighten” command, a fourth button 194 for initiating an“incremental loosen” command and a fifth button 195 for initiating an“open” (or fully loosen) command. Optionally, some embodiments couldinclude a “fully tighten” command that would tighten the footwear untila predetermined threshold is achieved (for example, a thresholdpressure, winding distance, etc.).

In some embodiments, a shoe, article, or other item may include morethan one motorized tightening device 160. In such embodiments, eachmotorized tightening device 160 may include wireless communicationhardware for separately communicating with a remote device 170, or asingle wireless communication device may be provided for common use bymultiple motorized tightening devices 160. For such embodiments, remotedevice 170 may be configured, such as with application 180, to provideadditional buttons or other controls to individually adjust pluralmotorized tightening devices 160 on a single article. For example,button 191 illustrated in FIG. 2 could be subdivided into a top regionand lower region which are separately responsive to user interaction. Byuse of these regions, one of two motorized tightening devices 160 couldbe selected for tension adjustment via buttons 193, 194, and 195. Inanother example, additional buttons like buttons 193 and 194 could bedisplayed at the same time by application 180, allowing for more rapidadjustment of multiple motorized tightening devices 160.

Application 180 may also include provisions for storing and usingpreferred tension settings. For example, sixth button 196 and seventhbutton 197 may be used to initiate a “store current tension” command anda “return to stored tension” command, respectively. In some cases, thetension values could be stored at the remote device, while in othercases the tension values could be stored in internal memory of a controlboard for the motorized tensioning device 160. Still other embodimentscould include provisions for storing multiple tension settings. Forexample, a user may prefer a tighter fit for playing sports and a looserfit for casual activities. In such cases, remote device 170 may allow auser to store two or more tension settings, corresponding to at leasttwo different lace tension preferences. In some embodiments, sixthbutton 196 may cause the tension setting for a single, currentlyselected, motorized tightening device 160 to be stored, and in someembodiments sixth button 196 may cause the tension settings for multiplemotorized tightening devices 160 to be stored in a single action. Thoseskilled in the art appreciate that storage or recall of tensions formultiple motorized tightening devices 160, whether part of a single itemof apparel or multiple items, such as a pair of shoes, may be performedwith a single command issued by a remote device 170 or with a series ofcontrol commands, such as by issuing separate control commands to eachmotorized tightening device 160 and/or item of apparel.

In some embodiments, application 180 and/or remote device 170 may beconfigured to selectively control individual items or individual sets ofitems, such as a pair of shoes, from among multiple items or sets ofitems within communication range of remote device 170. For example,application 180 may be configured to enumerate items by uniqueidentifiers assigned to each item, display the enumerated items to auser, and receive an input selecting an item. In another example, anapplication 180 may be paired via BlueTooth with a particular item orset of items. In another example, a remote device without an LCD displaymay include a control button that may be pressed, repeatedly if needed,to select a desired item, and the item may include an LED which isilluminated when it is in wireless communication with the remote device.

The embodiments are not limited to a particular user interface orapplication for remotely operating motorized tensioning device 160. Theembodiments here are intended to be exemplary, and other embodimentscould incorporate any additional control buttons, interface designs andsoftware applications. As one example, some embodiments may not includeprovisions for selecting the shoe to be controlled, and instead couldutilize two sets of control buttons, where each set corresponds toeither the left or right shoe. The control buttons for initiatingvarious operating commands can be selected according to various factorsincluding: ease of use, aesthetic preferences of the designer, softwaredesign costs, operating properties of the motorized tensioning device160 as well as possibly other factors.

Throughout the detailed description and in the claims, various operatingmodes, or configurations, of a tensioning system are described. Theseoperating modes may refer to states of the tensioning system itself, aswell as to the operating modes of individual subsystems and/orcomponents of the tensioning system. Exemplary modes include an“incremental tighten mode”, an “incremental loosen mode” and a “fullyloosen” mode. The latter two modes may also be referred to as an“incremental release mode” and a “full release mode”. In the incrementaltighten mode, motorized tightening device 160 may operate in a mannerthat incrementally (or gradually) tightens, or increases the tension of,lace 152. In the incremental loosen mode, motorized tightening device160 may operate in a manner that incrementally (or gradually) loosens,or releases tension in, lace 152. As discussed further below, theincremental tighten mode and the incremental loosen mode may tighten andloosen a lace in discrete steps or continuously. In the full releasemode, motorized tightening device 160 may operate in a manner so thattension applied to the lace by the system is substantially reduced to alevel where the user can easily remove his or her foot from the article.This is in contrast to the incremental release mode, where the systemoperates to achieve a lower tension for the lace relative to the currenttension, but not necessarily to completely remove tension from thelaces. Moreover, while the full release mode may be utilized to quicklyrelease lace tension so the user can remove the article, the incrementalrelease mode may be utilized to make minor adjustments to the lacetension as a user searches for the desired amount of tension. Althoughthe embodiments describe three possible modes of operation (andassociated control commands), other operating modes may also bepossible. For example, some embodiments could incorporated a fullytighten operating mode where motorized tightening device 160 continuesto tighten lace 152 until a predetermined tension has been achieved.

FIGS. 3 through 7 illustrate schematic views of an embodiment of article100 being tightened and loosened during different operating modes oftensioning system 150. Each figure also shows a schematic view of remotedevice 170, including the particular control button used to initiateeach operating mode.

FIG. 3 shows article 100 is in a fully opened state just prior to theentry of foot 200. In this state, lace 152 may be loose enough to allowa user to insert his or her foot into opening 130. Referring next toFIG. 4, foot 200 is inserted into article 100, which remains in thefully opened state. Referring next to FIG. 5, an incremental tightencommand has been sent to motorized tensioning device 160 by pressingthird button 193 of remote device 170. This command causes motorizedtensioning device 160 to enter an incremental tighten mode. At thispoint, the tension of lace 152 is increased to tighten upper 102 aroundfoot 200. In particular, lace 152 is drawn into motorized tensioningdevice 160, which pulls on the portions of lace 152 disposed adjacentthroat opening 132 and thus constricts throat opening 132. In somecases, this incremental tightening can occur in discrete steps so thateach time the wearer presses third button 193, lace 152 is taken up by apredetermined amount (for example by rotating a spool within motorizedtensioning device 160 through a predetermined angle). In other cases,this incremental tightening can occur in a continuous manner, as long asthe wearer continues to touch third button 193. In some cases, the speedof tightening can be set so that the system does not overshoot apreferred level of tightness (i.e., the system doesn't move between nottight enough and overly tight too quickly) while also being large enoughto avoid overly long times for fully tightening article 100.

FIGS. 6 and 7 illustrate schematic views of two different operatingmodes where lace 152 may be loosened. Referring first to FIG. 6, awearer can press fourth button 194 to initiate an incremental loosencommand in tensioning system 150. Upon receiving the incremental loosencommand, motorized tensioning device 160 may operate in an incrementalloosen mode, in which lace 152 is released from motorized tensioningdevice 160 (i.e., sections of lace 152 exit from motorized tensioningdevice 160). This relaxes some of the tension in lace 152 and allowsthroat opening 132 to partially expand. In some cases, this incrementalloosening can occur in discrete steps so that each time the wearerpresses fourth button 194, lace 152 is let out up by a predeterminedamount (for example by rotating a spool within motorized tensioningdevice 160 through a predetermined angle). In other cases, thisincremental loosening can occur in a continuous manner, as long as thewearer continues to touch fourth button 194. In some cases, the speed ofloosening can be set so that the system does not overshoot a preferredlevel of tightness (i.e., the system doesn't move between too tight andnot tight enough too quickly) while also being large enough to avoidoverly long times for fully loosening article 100. With thisarrangement, a wearer can continue increasing and decreasing the tensionof lace 152 (using the incremental tighten and incremental loosen modes)until a preferred level of tightness for upper 102 is achieved.

Referring next to FIG. 7, a wearer can press fifth button 195 toinitiate an open, or fully loosen, command in tensioning system 150. Incontrast to the incremental loosen command, the open command may be usedto quickly relieve all (or most of) tension in lace 152 so that a usercan quickly remove article 100. Thus, upon receiving the open command,motorized tensioning device 160 operates in a fully loosen mode. In thismode, motorized tensioning device operates to let out enough of lace 152so that substantially all tension is removed from lace 152. In somecases, this may be achieved by continuously monitoring tension in lace152 (for example, using sensors) and letting out lace 152 until thelevel of tension is below a threshold tension. In other cases, this maybe achieved by letting out a predetermined length of lace 152 known tocorrespond approximately to the amount needed to achieve a fullyloosened state for tensioning system 150. As seen in FIG. 7, withtensioning system 150 in the open state, foot 200 can be easily andcomfortably removed from footwear 100.

FIGS. 8 and 9 illustrate an isometric view and isometric exploded view,respectively, of an embodiment of the internal components of motorizedtensioning device 160. Referring first to FIG. 8, the components areshown within a portion of housing unit 212. Housing unit 212 may furtherinclude an inner housing portion 216 and an outer housing portion 218.Outer housing portion 218 may include a base panel 210 as well as anouter cover 214 (shown in FIG. 1), and generally provides a protectiveouter covering for components of motorized tensioning device 160. Innerhousing portion 216 may be shaped to support components of motorizedtensioning device 160. In some cases portions of inner housing portion216 function to limit the mobility of some components, as discussed indetail below.

Referring now to FIGS. 8 and 9, in some embodiments, motorizedtensioning system 160 may comprise motor 220 (shown schematically inFIG. 9). In some embodiments, motor 220 may be an electric motor.However, in other embodiments, motor 220 could comprise any kind ofnon-electric motor known in the art. Examples of different motors thatcan be used include, but are not limited to: DC motors (such aspermanent-magnet motors, brushed DC motors, brushless DC motors,switched reluctance motors, etc.), AC motors (such as motors withsliding rotors, synchronous electrical motors, asynchronous electricalmotors, induction motors, etc.), universal motors, stepper motors,piezoelectric motors, as well as any other kinds of motors known in theart. Motor 220 may further include a motor crankshaft 222 that can beused to drive one or more components of motorized tensioning system 160.Provisions for powering motor 220, including various kinds of batteries,are discussed in detail below.

In some embodiments, motorized tensioning system 160 can includeprovisions for reducing the output speed of, and increasing the torquegenerated by, motor 220. In some embodiments, motorized tensioningsystem 160 can include one or more gear reduction assemblies and/or gearreduction systems. In some embodiments, motorized tensioning system 160may include a single gear reduction assembly. In other embodiments,motorized tensioning system 160 may include two or more gear reductionassemblies. In one embodiment, motorized tensioning system 160 includesfirst gear reduction assembly 230 and second gear reduction assembly232, which may be collectively referred to as gear reduction system 228.First gear reduction assembly 230 may be an in-line spur gear reductionassembly that is generally aligned with motor 220 and/or crankshaft 222.In contrast, second gear reduction assembly 232 may provide additionalgear reduction that extends in a generally perpendicular direction tothe orientation of crankshaft 222. With respect to housing unit 212,first gear reduction assembly 230 may extend in a longitudinal directionof housing unit 212 while second gear reduction assembly 232 may extendin a lateral (or horizontal) direction of housing unit 212. By using acombination of in-line gears and horizontally spaced gears, relative tothe orientation of crankshaft 222, motor 220 can be arranged in parallelwith a spool and corresponding spool shaft (as discussed in furtherdetail below). This arrangement may reduce the longitudinal spacerequired to fit all the components of motorized tensioning device 160within housing unit 212.

Each gear reduction assembly can comprise one or more gears. In theexemplary embodiment, first gear reduction assembly 230 comprises one ormore in-line spur gears. Moreover, first gear reduction assembly 230 maybe driven by crankshaft 222 and itself drives a first gear 234 of secondgear reduction assembly 232.

In one embodiment, second gear reduction assembly 232 may be configuredwith 4 stages of spur gears, including a first gear 234, a second gear235, a third gear 236 and a fourth gear 237. In this embodiment, fourthgear 237 acts as a clamping gear for turning additional components ofmotorized tensioning device 160, as described in further detail below.The current embodiment of second gear reduction assembly 232 includesfour gears. However, other embodiments could use any other number ofgears. Likewise, the number of gears comprising first gear reductionassembly 230 may vary in different embodiments. Additionally, indifferent embodiments, the type of gears used in first gear reductionassembly 230 and/or second gear assembly 232 could vary. In some cases,spur gears may be used. Other examples of gears that may be usedinclude, but are not limited to: helical gears, external gears, internalgears, bevel gears, crown gears, worm gears, non-circular gears, rackand pinion gears, epicyclic gears, planetary gears, harmonic drivegears, cage gears, magnetic gears as well as any other kinds of gearsand/or any combinations of various kinds of gears. The number, type andarrangement of gears for gear reduction system 228 may be selected toachieve the desired tradeoff between size, torque and speed of themotorized tensioning system 160.

In some embodiments, motorized tensioning system 160 can includeprovisions for winding and unwinding portions of a lace. In someembodiments, motorized tensioning system 160 can include spool 240. Insome cases, spool 240 may further comprise a first receiving portion 242and a second receiving portion 244 for receiving a lace and a portion ofa spring, respectively. Moreover, in some cases, first receiving portion242 may comprise a first lace winding region 246 and a second lacewinding region 248, which in some cases can be used to separately windtwo ends of a lace. Since torque output goes down as the lace builds upin diameter, using separate winding regions for each lace end may helpdecrease the diameter of wound lace on spool 240 and thereby minimizetorque output reduction. In some cases, first lace winding region 246and second lace winding region 248 may be separated by a dividingportion 249, which may include a lace receiving channel 247 forpermanently retaining a portion of the lace on spool 240. In othercases, however, first receiving portion 242 may comprise a single lacewinding region.

Motorized lacing system 160 may include provisions for transferringtorque between a final drive gear of second gear reduction assembly 232and spool 240. In some embodiments, motorized lacing system 160 mayinclude provisions for transferring torque from second gear reductionassembly 232 (or more generally from gear reduction system 228) to spool240 in a manner that allows for incremental tightening, incrementalloosening and full loosening of a lace. In one embodiment, motorizedlacing system 160 may be configured with a torque transmitting system250 that facilitates the transmission of torque from fourth gear 237 ofsecond gear reduction assembly 232 to spool 240.

Torque transmitting system 250 may further comprise various assembliesand components. In some embodiments, torque transmitting system 250 mayinclude a ratcheting assembly 252, a shaft 254 and a rotation controlassembly 256. As discussed in further detail below, the components oftorque transmitting system 250 operate to transmit torque from fourthgear 237 of second gear reduction assembly 232 to spool 240. Morespecifically, these components operate in a manner that allows forincremental tightening (spool winding), incremental loosening (spoolunwinding) as well as full tension release (during which timesubstantially no torque is transferred from fourth gear 237 to spool240).

In some embodiments, motorized tensioning device 160 may further includea secondary winding assembly 260. In some embodiments, secondary windingassembly 260 may be configured to apply torque to spool 240independently of any torque applied by motor 220. In some cases, forexample, secondary winding assembly 260 comprises a spring member 262and a rotatable spring bearing 264. Spring member 262 may extendsbetween second receiving portion 244 of spool 240 and spring bearing264. In particular, a first end portion 263 of spring member 262 may beassociated with spool 240 while a second end portion 265 of springmember 262 may be associated with spring bearing 264. In operation,spring member 262 may be configured to apply a biasing torque that maytend to rotate spool 240 in the lace winding direction in the absence ofother forces or torques (for example when there is slack in the lace).Spring member 262 could be a wind-up spring, a constant force spring, aconstant torque spring, a clock spring as well as any other kind ofspring.

Some embodiments can also include a fixed bearing 266, which may beassociated with an end of shaft 254. In some embodiments, fixed bearing266 may be received within a recess 268 of inner housing portion 216. Insome embodiments, an end of shaft 254 may be disposed within opening 269of fixed bearing 266, and may be configured so that shaft 254 can slidethrough opening 269 to provide some axial movement for shaft 254.

In some embodiments, motorized tensioning device 160 may includeprovisions for adjusting the operation of motor 220 according to one ormore feedback signals. In some embodiments, for example, motorizedtensioning device 160 may include a limit switch assembly 258.Generally, limit switch assembly 258 may detect current across portionsof rotation control assembly 256 and vary the operation of motor 220according to the detected current. Further details on the operation oflimit switch assembly 258 are discussed in detail below.

For purposes of reference, the following detailed description uses theterms “first rotational direction” and “second rotational direction” indescribing the rotational directions of one or more components about anaxis. For purposes of convenience, the first rotational direction andthe second rotational direction refer to rotational directions about alongitudinal axis 284 (see FIG. 12) of shaft 254 and are generallyopposite rotational directions. The first rotational direction may referto the clockwise rotation of a component about longitudinal axis 284,when viewing the component from the vantage point of first end portion620 of shaft 254. First end portion 620 of shaft 254 may be the endportion associated with fourth gear 237. The second rotational directionmay be then be characterized by the counterclockwise rotation of acomponent about longitudinal axis 284, when viewing the component fromthe same vantage point.

A brief overview of the operation of motorized tensioning device 160 isdescribed here. A detailed description of the operation is given below.In the incremental tighten mode motor 220 may begin operating in orderto rotate crankshaft 222. Crankshaft 222 may turn an input gear of firstgear reduction assembly 230, such that the output gear of first gearreduction assembly 230 drives first gear 234 of second gear reductionassembly 232. The intermediate second gear 235 and third gear 236 bothrotate, which drives fourth gear 237 in the first rotational direction.As fourth gear 237 rotates, fourth gear 237 may engage and drive torquetransmitting system 250 such that spool 240 may eventually begin torotate in the first rotational direction. This causes lace 152 to windonto first receiving portion 242 of spool 240.

In the incremental loosen mode, motor 220 may operate to rotatecrankshaft 222. In the loosening mode, motor 220 and crankshaft 222 turnin an opposite direction of the direction associated with tightening.The gear reduction system 228 is then driven such that fourth gear 237of second gear reduction assembly 232 rotates in the second rotationaldirection. In contrast to the incremental tighten mode, in theincremental loosen mode fourth gear 237 does not directly drive portionsof torque transmitting system 250 and spool 240. Instead, the motion offourth gear 237 in the second rotational direction causes torquetransmitting system 250 to momentarily release spool 240, allowing spool240 to unwind by a predetermined amount after which torque transmittingsystem 250 reengages spool 240 and prevents further unwinding. Thissequence of releasing and catching spool 240 occurs over and over aslong as fourth gear 237 rotates in the second rotational direction.Further details of the method by which this incremental loosening isachieved is described in detail below.

Finally, in the open or fully loosen mode, torque transmitting system250 operates so that substantially no torque is transmitted to spool 240from any components of torque transmitting system 250. During this mode,spool 240 may rotate more easily in the unwinding direction about shaft254 (for example, as a wearer manually loosens lace 152 to take offarticle 100). As slack forms along the lace, secondary winding assembly260 may apply a small amount of torque to second receiving portion 244of spool 240, which acts to wind up slack in lace 152.

Torque Transmitting System

FIGS. 10-14 illustrate various schematic views of the componentscomprising torque transmitting system 250. For purposes of clarity,these components are shown in isolation from other parts of motorizedtightening device 160. Additionally, some components are not shown ormay be shown in phantom in some views to reveal interior components.

Referring first to FIGS. 10 and 11, ratcheting assembly 252 may compriseseveral components including fourth gear 237, pawl member 600 andratchet housing 602 (ratchet housing 602 is not shown in FIG. 11 tobetter show the relative positions of fourth gear 237, pawl member 600and spool 240). Fourth gear 237 may include an extended boss portion604. In some embodiments, the extended boss portion 604 further includesa frictional face 606 that contacts pawl member 600. Fourth gear 237 mayalso include an internally threaded cavity 608 that may engage threadingon shaft 254. For purposes of convenience, fourth gear 237 ischaracterized as part of both ratcheting assembly 252 and second gearreduction assembly 232 as fourth gear 237 acts as an element thatconfronts and directly drives pawl member 600 and also as a finaldriving gear of second gear reduction assembly 232. In particular, it isto be understood that characterizing fourth gear 237 as part of oneassembly does not preclude it from being associated with a differentassembly.

In some embodiments, pawl member 600 is configured to interface withratchet housing 602. In particular, teeth 610, which extend from pawlarms 611, may engage with corresponding teeth 612 on ratchet housing602. In some cases the geometry of pawl arms 611 and teeth 610 providean arrangement where pawl member 600 can rotate within ratchet housing602 in a first rotational direction, but pawl member 600 is preventedfrom rotating within ratchet housing 602 in a second rotationaldirection that is opposite of the first rotational direction.

In some embodiments, pawl member 600 includes a boss engaging surface614 that confronts and can engage frictional face 606 of fourth gear237. When frictional face 606 of fourth gear 237 is brought into contactwith boss engaging surface 614 of pawl member 600, fourth gear 237 maydrive pawl member 600. Moreover, the one-way ratchet design ofratcheting assembly 252 ensures that fourth gear 237 may only drive pawlmember 600 in a first rotational direction.

Pawl member 600 may include a spool engaging surface 616 (see also FIG.16) which confronts a first end 670 of spool 240. When spool engagingsurface 616 is pressed against spool 240 with enough frictional force,pawl member 600 may be used to drive spool 240 in the first rotationaldirection. Thus, in the configuration shown in FIG. 11, with fourth gear237, pawl member 600 and spool 240 all clamped together under sufficientfrictional force, fourth gear 237 may act to drive pawl member 600 andthus spool 240.

Ratcheting assembly 252 is only intended to be exemplary of a one-waytorque transmitting mechanism that may be used to transmit torque to aspool. Other embodiments are not limited to ratchet-like mechanisms andcould include other one-way mechanisms. Examples of other one-waymechanisms that could be used include, but are not limited to: rollerbearings, sprag clutches, ratcheting wheel and pawl as well as othermechanisms.

FIGS. 12-14 illustrate various views of additional components of torquetransmitting system 250, including shaft 254 and rotation controlassembly 256. In particular, FIG. 12 illustrates an isolated explodedview of shaft 254 and rotation control assembly 256, while FIGS. 13-14illustrate assembled views of some portions of these components fromvarious perspectives.

Shaft 254 may comprise a first end portion 620. In some embodiments,first end portion 620 may include threading 624. In some cases,threading 624 may engage internally threaded cavity 608 (see FIG. 10) offourth gear 237, which may facilitate the relative axial movement offourth gear 237 along shaft 254. Shaft 254 may also include a second endportion 622 that engages opening 269 of fixed bearing 266. In someembodiments, an intermediate portion 626 of shaft 254 may be disposedbetween first end portion 620 and second end portion 622.

Various portions of shaft 254 are configured to receive components oftorque transmitting system 250 and spool 240. First end portion 620 andsecond end portion 622 may be associated with ratcheting assembly 252and rotation control assembly 256, respectively. Intermediate portion626 may be inserted within a central cavity 690 of spool 240 (see FIG.15), such that spool 240 may rotate about intermediate portion 262.

In some embodiments, intermediate portion 626 of shaft 254 furtherincludes a flange portion 628 that extends radially outwards from shaft254. Flange portion 628 may include a spool engaging surface 630 thatcontacts spool 240. An opposing surface of flange portion 628 (notshown) may confront rotation control assembly 256. In some embodiments,flange portion 628 may include one or more slots 632.

In some embodiments, rotation control assembly 256 may include anengagement plate 640 and a compression spring 642. In some embodiments,engagement plate 640 further includes pins 644 that extend towardsengagement plate 640 and spool 240. In some embodiments, pins 644 may beinserted through slots 632 of flange portion 628. Moreover, in somecases, pins 644 may be inserted into alignment holes 650 of spool 240(see FIG. 15), which prevents shaft 254 and spool 240 from rotatingindependently of one another.

As seen in FIGS. 12-14, the components of rotation control assembly 256are disposed along second end portion 622 of shaft 254. In someembodiments, compression spring 642 may be disposed between engagementplate 640 and fixed bearing 266 so that compression spring 642 may actto bias engagement plate 640 in an axial direction towards flangeportion 628 and spool 240.

In other embodiments, alternate methods could be used for releasablycoupling a shaft and spool. Examples include other kinds of physicalinterlocking features or including friction increasing features. As oneexample, axial compliant friction coupling could be achieved using awave washer or Belleville washer.

FIG. 15 illustrates an isometric view of an embodiment spool 240 inisolation. As previously described, spool 240 includes provisions forreceiving pins 644 of engagement plate 640. In this case, four alignmentholes 650 are approximately evenly spaced about a second end face 673.Additionally, this particular view of spool 240 clearly illustrates aslot 675 that may be used for retaining an end of spring member 262.

Referring now to FIG. 16, the components of torque transmitting system250 are shown in their assembled configuration along shaft 254. Forpurposes of reference, spool 240 is shown in phantom on shaft 254. Inaddition, a cross-sectional portion of inner housing portion 216 isshown for reference. As also seen in FIG. 8, when installed within innerhousing portion 216, some components of torque transfer system 250 areconstrained from any axial movement. For example, spool 240 and ratchethousing 602 are constrained from moving in an axial direction (or alonga longitudinal direction of shaft 254). In contrast, fourth gear 237,which is threaded along first end portion 620 of shaft 254, can rotateabout shaft 254 and translate axially (because of the threadedengagement) along shaft 254. In some embodiments, a wall portion 652 ofinner housing portion 216 limits the axial motion of fourth gear 237 ina direction away from ratcheting assembly 252.

The arrangement shown here for torque transmitting system 250 alsoallows for both rotation and axial translation of shaft 254. Inparticular, second end portion 622 of shaft 254 may slide through fixedbearing 266, while first end portion 620 of shaft 254 is disposed in achannel 660 of inner housing portion 216 (see FIG. 8) that also allowsfor some axial motion of shaft 254. In some embodiments, the amount ofaxial translation may be limited by features including contact betweenflange portion 628 and spool 240, as well as possibly other features.

FIGS. 17 through 26 illustrate schematic views of torque transmittingsystem 250 and spool 240 for purposes of illustrating the operation oftorque transmitting system 250 during incremental tightening,incremental loosening and full loosening. Referring first to FIG. 17,torque transmitting system 250 is in a configuration where the lace isfully loosened. More specifically, this configuration is one in which notorque is transmitted to spool 240 from torque transmitting system 250.In this configuration, fourth gear 237 may be spaced away from pawlmember 600 (disposed within ratchet housing 602) so that no torque istransmitted from fourth gear 237 to pawl member 600. Furthermore,without fourth gear 237 to provide any clamping pressure against pawlmember 600 and spool 240, spool 240 may rotate without any substantialresistance at first end portion 670 from pawl member 600. Furthermore,in this configuration engagement plate 640 and flange portion 628 arespaced apart from second end 672 of spool 640, so that spool 240 alsodoes not undergo any resistance to rotation at second end 672. Althoughfeatures of inner housing portion 612 prevent any axial motion of spool240, in this configuration spool 240 may rotate in a first rotationaldirection or a second rotational direction. As previously described,spool 240 may be biased to rotate in a first rotational direction (i.e.,lace winding direction) by secondary winding assembly 260 (not shown),which applies a biasing torque to spool at second receiving portion 244.However, this biasing force may be just large enough to pull in slackand can be overcome relatively easily by a wearer pulling on the lacesto unwind them from spool 240. Thus, spool 240 may rotate relativelyfreely in this configuration, though spool 240 will be biased to wind inslack in the absence of tension applied by the lace to spool 240.

As also shown in FIG. 17, in this fully loosened configuration thecontacts 259 of limit switch assembly 258 are pressed against engagementplate 640. This contact with engagement plate 640 provides continuityfor the switch, so that current may flow between contacts 259.

FIG. 18 shows the operation of torque transmitting system 250 as motor220 (not shown) begins to rotate. Initially, motor 220 drives gearreduction system 228, so that fourth gear 237 is rotated in the firstrotational direction (represented schematically by arrow 700). As fourthgear 237 rotates in the first rotational direction, fourth gear 237translates axially (indicated by arrow 702) towards pawl member 600because of the threaded interface between fourth gear 237 and shaft 254.Fourth gear 237 continues to rotate and translate axially untilfrictional face 606 of boss portion 604 contacts and presses againstboss engaging surface 614 of pawl member 600. At this point, the preloadfrom compression spring 642 may provide some drag on engagement plate640 and flange portion 628 (which are coupled) to keep shaft 254 fromrotating while fourth gear 237 translates axially along shaft 254.Without this drag, or another source of friction or drag, shaft 254 maybe inclined to turn with fourth gear 237 so that fourth gear 237 wouldnot translate axially.

FIG. 19 shows the operation of torque transmitting system 250 in aconfiguration where spool 240 may begin to wind in lace (i.e., torquetransmitting system 250 is in the incremental tighten mode). In thiscase, motor 220 continues to drive fourth gear 237 in the firstrotational direction (indicated schematically as arrow 700), thoughcontact with pawl member 600 prevents any further axial translation offourth gear 237 along shaft 254. Therefore, as fourth gear 237 continuesto turn, shaft 254 is translated axially (indicated schematically asarrow 706) so that first end portion 620 translates further from spool240. As shaft 254 translates axially, flange portion 628 compressesagainst second end 672 of spool 240, allowing pins 644 to engagealignment holes (see FIG. 15) of spool 254. This locks shaft 254 andspool 240 together and prevents relative rotation of the two components.The contact between between flange portion 628 and spool 240 preventsany further axial translation of shaft 254. At this point, withratcheting assembly 252 clamped against first end portion 670 of spool240, further driving of fourth gear 237 acts to rotate spool 240 in thefirst rotational direction (indicated schematically by arrow 708). Aslong as motor 240 continues to drive fourth gear 237, lace may be woundonto spool 240.

It can also be seen in FIG. 19 that as flange 628 moves towards spool240 and engagement plate 640 follows under the force of compressionspring 642, limit switch assembly 258 is separated from engagement plate640. This breaks the continuity of current between contacts 259.

FIGS. 20 and 21 illustrate close up schematic views of some components.For purposes of illustration, a schematic lace 720 is shown with spool240. Referring to FIGS. 20 and 21, ratcheting assembly 252 ensures thattorque can only be transmitted from fourth gear 237 to pawl member 600and spool 240, and not vice versa. In particular, the one-way operationof ratcheting assembly 252 prevents torque generated by spool 240 fromturning pawl member 600, fourth gear 237 and ultimately motor 220. Inother words, as previously described, ratcheting assembly 252 functionsas a load-holding mechanism that prevents spool 240 from unintentionallyrotating in the second rotational direction (i.e., the unwindingdirection). This arrangement may help prevent spool 240 from backwinding motor 220 in situations where motor 220 stops or the torqueapplied to spool 240 by the lace exceeds to torque applied to the spoolby fourth gear 237.

FIGS. 22-25 show the operation of torque transmitting system 250 in anincremental loosen mode. In some embodiments, incremental loosening mayoccur in several stages. During a first stage, shown in FIGS. 22 and 23,motor 220 is operated to drive fourth gear 237 in the second rotationaldirection (indicated schematically as arrow 730). This causes fourthgear 237 to translate axially away from pawl member 600 and spool 240 ina direction indicated schematically by arrow 732. As fourth gear 237translates away from pawl member 600, the clamping force between fourthgear 237, pawl member 600 and first end 670 of spool 240 is released.During a second stage, shown in FIG. 24, tension in the lace then causesspool 240 to rotate in the second rotational direction (indicatedschematically by arrow 734). Because spool 240 and shaft 254 arephysically locked together at this stage, shaft 254 rotates along withspool 240 in the second rotational direction (indicated schematically byarrow 736). As shaft 254 rotates the threaded engagement between shaft254 and fourth gear 237 (as well as the resistance to the rotation offourth gear 237 provided by gear reduction system 228 and motor 220)causes fourth gear 237 to translate axially towards pawl member 600. Inthe last stage, shown in FIG. 25, fourth gear 237, pawl member 600 andspool 240 are clamped together, which prevents spool 240 from furtherrotation in the second rotational direction. These three stages may berepeated in succession to incrementally unwind lace from spool 240.

FIG. 26 shows the operation of torque transmitting system 250 in a fullyloosen mode (or full release mode). Referring to FIG. 26, motor 220 maydrive fourth gear 237 to rotate in the second rotational direction(indicated schematically by arrow 740) until the lace tension is lowenough that spool 240 no longer unwinds. In some embodiments, fourthgear 237 may continue to rotate until fourth gear 237 encounters a hardstop provided by wall portion 652 of inner housing portion 216. Withfourth gear 237 unable to translate further, continued driving of fourthgear 237 by motor 220 results in shaft 254 translating axially in thedirection indicated schematically by arrow 742 until engagement plate628 is no longer locked with spool 240 (i.e., until pins 644 disengagedfrom alignment holes 650 of spool 240). At this point, engagement plate640 touches contacts 259 of limit switch assembly 258, therebycompleting the limit switch continuity, which further causes motor 220to stop. This leaves spool 240 in a fully loosened state and able torotate relatively freely, though with some biasing in the firstrotational direction provided by secondary winding assembly 260.

Secondary Winding Assembly

A secondary winding assembly may be configured to operate substantiallyindependently of a torque transmitting system. This may allow thewinding assembly to draw in slack during various stages of operation ofthe torque transmitting system. In particular, the secondary windingassembly may be configured to draw in slack in a tensioning member(e.g., lace), which could occur during tightening, loosening and fullyloosening of the tensioning member.

FIGS. 27 through 29 illustrate schematic isometric views of someportions of motorized tightening device 160. More specifically, FIGS. 27through 29 are intended to illustrate the general operation of secondarywinding assembly 260 during different operating modes of the system.FIG. 27 illustrates a configuration of motor tightening device 160operating in a tightening mode. In this mode, fourth gear 237, incooperation with torque transmitting system 250, drives spool 240 in afirst rotational direction and thereby winds lace 800 around spool 240.In this mode, spring member 262 may be wound from spool 240 to springbearing 264 as spool 240 is driven by the motor.

Referring next to FIG. 28, when motorized tightening device 160 operatesin a fully loosened mode, the tension of lace 800 rotates spool 240 inthe second winding direction and unwinds lace 800 from spool 240. Asspool 240 winds in the second rotational direction, spring member 262may unwind from spring bearing 264 and onto second receiving portion 244of spool 240. This allows spring member 262 to return to a defaultconfiguration, in which secondary winding assembly 260 tends to biasspool 240 in the winding direction to draw in slack.

Referring next to FIG. 29, motorized tightening device 160 is operatingin a mode where no torque is being supplied to spool 240 by a motor. Inaddition, slack has developed in lace 800 so that lace 800 is notapplying much torque to spool 240 either. In this situation, secondarywinding assembly 260 provides a biasing force to wind spool 240 in thefirst rotational direction, as spring member 262 unwinds from secondreceiving portion 244 of spool 240 and onto spring bearing 264.

Secondary winding assembly 260 may improve usability of tensioningsystem 150, by ensuring that slack is rapidly wound up when motor 220 isdisengaged. This is desirable so a user can quickly put the article onor take the article off without having to wait for the motor to wind inslack. In the embodiment shown, this rapid slack winding is accomplishedusing constant force spring that is stored on a freewheeling spool andrewound onto one end of the lace spool. However, in other embodiments, avariety of different elements or systems could be used for this rapidslack winding. For example, in another embodiment a second small motorwith either no reduction or light gear reduction could be used for slackwinding. In still other embodiments, other spring elements could beused. For example, in another embodiment, an elastomeric torsion springcould be used. In still another embodiment, a geared clock spring couldbe used. Moreover, in other embodiments, a spring member could be woundonto other components of a tightening system. For example, in thealternative embodiment shown in FIG. 30, spring member 820 is configuredto wind around spool 240 at one end, and around motor 220 at another.This alternative arrangement may provide a slightly more compactconfiguration for a motorized tightening system. In addition toimproving the speed of fully winding and unwinding the lace, batterylife may be greatly improved over systems that utilize a motor tocompletely wind and unwind a lace.

Placement

The location of a motorized tensioning device can vary from oneembodiment to another. The illustrated embodiments show a motorizedtensioning device disposed on the heel of an upper. However, otherembodiments may incorporate a motorized tensioning device in any otherlocation of an article of footwear, including the forefoot and midfootportions of an upper. In still other embodiments, a motorized tensioningdevice could be disposed in a sole structure of an article. The locationof a motorized tensioning device may be selected according to variousfactors including, but not limited to: size constraints, manufacturingconstraints, aesthetic preferences, optimal lacing placement, ease ofremovability as well as possibly other factors.

In embodiments where motorized tensioning device 160 is disposedexternally on upper 102, a wearer may access components by removing aportion of housing unit 212 (see FIG. 1). For example, in some casesspool 240 may be replaceable in the event of a broken lace.

Some embodiments may include provisions for incorporating a motorizedtensioning device into removable components of an article. In oneembodiment, a motorized tensioning device may be incorporated into anexternal heel counter. In some cases, an external heel counter mayfunction as a harness for mounting a motorized tensioning device to anarticle. In such embodiments, the external heel counter may be speciallyadapted to receive a motorized tensioning device. An example of a heelcounter configured for use with a lace tensioning device is disclosed inGerber, U.S. Pat. No. 10/004,295, now U.S. patent application Ser. No.13/481,132, filed May 25, 2012 and titled “Article of Footwear withProtective Member for a Control Device”, the entirety of which is herebyincorporated by reference.

Battery and Control Unit

Embodiments may include a battery and/or control unit configured topower and control motorized tensioning device 160. FIG. 31 illustrates aschematic view of an embodiment of article 100 including motorizedtensioning device 160, battery 300 and control unit 302. In theembodiment of FIG. 31, motorized tensioning device 160, battery 300 andcontrol unit 302 are all disposed in an external heel counter 304, whichmay function to receive and protect these components. In otherembodiments, however, any of these components could be disposed in anyother portions of an article, including the upper and/or sole structure.In some cases, some components could be disposed in one portion of anarticle and other components could be disposed in another, different,portion. In another embodiment motorized tensioning device 160 could bedisposed at the heel of an upper, while battery 300 and/or control unit302 could be disposed with a sole structure of article 100. For example,in one embodiment the battery and controller unit may be disposed undermidfoot portion 12 of article 100 with a cable connection (or a simpleelectrical contact connection) to motorized tensioning device 160, whichmay be disposed in heel portion 14. In still other embodiments, abattery and a control unit could be integrated into a motorizedtensioning device. For example, in some embodiments, both a battery anda control unit could be disposed within housing unit 212 (see FIG. 1) ofmotorized tensioning device 160.

Battery 300 is only intended as a schematic representative of one ormore types of battery technologies that could be used to power motorizedtightening device 160. One possibly battery technology that could beused is a lithium polymer battery. The battery (or batteries) could berechargeable or replaceable units packaged as flat, cylindrical, or coinshaped. In addition, batteries could be single cell or cells in seriesor parallel.

Rechargeable batteries could be recharged in place or removed from anarticle for recharging. In some embodiments, charging circuitry could bebuilt in and on board. In other embodiments, charging circuitry could belocated in a remote charger. In another embodiment, inductive chargingcould be used for charging one or more batteries. For example, acharging antenna could be disposed in a sole structure of an article andthe article could then be placed on a charging mat to recharge thebatteries.

Additional provisions could be incorporated to maximize battery powerand/or otherwise improve use. For example, it is also contemplated thatbatteries could be used in combination with super caps to handle peakcurrent requirements. In other embodiments, energy harvesting techniquescould be incorporated which utilize the weight of the runner and eachstep to generate power for charging a battery.

Control unit 302 is only intended as a schematic representation of oneor more control technologies that could be used with motor tensioningdevice 160. For example, there are various approaches to motor controlthat may be employed to allow speed and direction control. For someembodiments, a microcontroller unit may be used. The microcontroller mayuse internal interrupt generated timing pulses to create pulse-widthmodulation (PWM) output. This PWM output is fed to an H-bridge whichallows high current PWM pulses to drive the motor both clockwise andcounterclockwise with speed control. However, any other methods of motorcontrol known in the art could also be used.

Apparel

A tensioning system as described above is not limited to articles offootwear and could be used with apparel, for example. As one particularexample, FIGS. 32-36 illustrate an embodiment where a tensioning system320 is used with an article of apparel 322. In this case, article ofapparel 322 may be a layer of clothing that incorporates shoulder pads324. For purposes of clarity, the description below discusses the use oftensioning system 320 for adjusting a first shoulder pad 326, however,it will be understood that a substantially similar tensioning systemcould also be used to adjust a second shoulder pad 328 in a similarmanner.

As seen in FIG. 32, the embodiment discussed here may be used forpadding worn by a user 330 playing American football, where shoulderpads are common. However, other embodiments could use this adjustableshoulder pad configuration with any other kinds of clothing configuredto be worn by players in any other sports, including, for example,hockey, lacrosse, as well as any other sports or activities requiringshoulder pads. Moreover, it should be understood that the principlesdiscussed here can be used for adjusting any kinds of padding including,but not limited to: elbow pads, knee pads, shin pads, padding associatedwith the hands and arms, padding associated with the feet and legs,padding associated with the torso, padding associated with the head aswell as any other kind of padding known in the art.

Referring now to FIGS. 33 and 34, first shoulder pad 326, referred tohereafter simply as pad 326, may comprise a plurality of paddingelements 340. In one embodiment, the geometry of these padding elements340 is approximately hexagonal. Moreover, the plurality of paddingelements 340 may be spaced apart from one another in a defaultconfiguration of pad 326.

In order to control the spacing between plurality of padding elements340, some embodiments can utilize tensioning system 320 to apply aninwardly tensioning force that squeezes plurality of padding elements340 closer together. In some embodiments, tensioning system 320 mayinclude a motorized tensioning device 342 and a cable 344. In someembodiments, motorized tensioning device 342 is mounted onto article ofapparel 322 at a location adjacent to pad 326. Cable 344 extends frommotorized tensioning device 342 and wraps around a perimeter of pad 326,thereby surrounding the outer most elements of plurality of paddingelements 340. In some cases, cable 344 may be placed through one or morecable guides or lace guides, however in other cases cable 344 may wraparound the perimeter of pad 326 without the use of any guides.

In the default configuration cable 344 is generally loose and applies notension to pad 326. This is the configuration shown, for example, inFIG. 33. In order to compress or tighten pad 326, user 330 may press theincremental tightening button 346 on remote device 348, which sendstensioning commands to motorized tensioning device 342 (or to a separatecontrol unit of motorized tensioning device 342). As cable 344 istightened (see FIGS. 34 and 36), cable 344 applies an inward tensioningforce on the outer most elements of plurality of padding elements 340,which may squeeze plurality of padding elements 340. This decreases thespacing between adjacent padding elements 340 and increases the overalldensity of pad 326, which may increase the overall stiffness of pad 326as compared to the stiffness of pad 326 in the default configuration. Inother words, motorized tensioning device 342 may be used to adjust thestiffness of pad 326 from a first stiffness associated with anon-tensioned state of cable 344 to a second stiffness associated with atensioned state of cable 344, where the second stiffness issubstantially greater than the first stiffness. This feature may be usedto adjust padding stiffness according to playing conditions (dry, wet,turf, grass, etc.) as well as activity type (practice vs. game) or anyother factors.

A tensioning system including a motorized tensioning device may be usedwith any other kinds of apparel. Some examples of other apparel areshown in FIG. 37, which illustrates schematic views of a backpack 350and a hat 354, and a corresponding first tensioning system 356 andsecond tensioning system 358, respectively. For example, firsttensioning system 356 may apply tension to a cable 372, which adjuststhe tightness of straps 374 of backpack 350. Likewise, second tensioningsystem 358 may apply tension to a cable or band 380 that circumscribesthe periphery of hat 354 and therefore can be used to adjust the size ofopening 382 of hat 354.

Further examples of articles that can be used with tensioning systemsare disclosed in Soderberg et al., U.S. Patent Application PublicationNumber 2010/0139057, now U.S. patent application Ser. No. 12/623,362,filed Nov. 20, 2009 and titled “Reel Based Lacing System” (the “'362application”), the entirety of which is hereby incorporated byreference. Still further examples of articles that can be used withtensioning systems are disclosed in Soderberg et al., U.S. PatentApplication Publication Number 2009/0184189, now U.S. patent applicationSer. No. 12/355,675, filed Jan. 16, 2009 and titled “Closure System”(the “Closure system application”), the entirety of which is herebyincorporated by reference. It is contemplated that in some embodiments amotorized tensioning device could be incorporated into the articlesdescribed in the '362 application as well as articles described in theClosure system application, including a helmet, a hat, a glove, abackpack and/or hydration carrier, a belt, bindings for boots, a wristguard and a sandal.

In still other embodiments, a tensioning system including a motorizedtensioning device can be used with any other kinds of apparel and/orsports equipment including, but not limited to gloves, shirts, pants,socks, scarves, jackets, as well as other articles. Other examples ofarticles include, but are not limited to: shin guards, knee pads, elbowpads, shoulder pads, as well as any other type of protective equipment.Additionally, in some embodiments, the flexible manufacturing systemcould be used with bags, duffel bags, purses, backpacks, luggage,various kinds of sportswear and/or sporting equipment.

Alternative Controls

In different embodiments, control of a motorized lacing device can beaccomplished using various methods and devices. Referring now to FIG.38, some embodiments may utilize various kinds of remote devices,including an RF based control bracelet 390. Control bracelet 390 mayincorporate one or more buttons for sending commands to a motorizedtensioning device. In some cases, control bracelet 390 may includebuttons for initiating incremental tightening and incremental looseningcommands. In still other cases, additional buttons can be included forinitiating any other commands including the open command (or fullyloosen command), store tension command and return to stored tensioncommand. Still other cases could incorporate any other buttons forissuing any other kinds of commands.

In some other embodiments, buttons for tightening, loosening and/orperforming other functions can be located directly on an article. As anexample, some embodiments could incorporate one or more buttons locatedon or adjacent to the housing of a motorized tensioning device. In stillother embodiments, a motorized tightening device maybe controlled usingvoice commands. These commands could be transmitted through a remotedevice, or to a device capable of receiving voice commands that isintegrated into the article and in communication with the motorizedtensioning device.

Sensors

Embodiments can incorporate a variety of sensors for providinginformation to a control unit of a motorized tensioning system. Asdescribed above, in some embodiments an H-bridge mechanism is used tomeasure current. The measured current is provided as an input to controlunit 302 (see FIG. 31). In some cases, a predetermined current may beknown to correspond to a certain lace tension. By checking the measuredcurrent against the predetermined current, a motorized tensioning systemmay adjust the tension of a lace until the predetermined current ismeasured, which indicates the desired lace tension has been achieved.

With current as a feedback, a variety of digital control strategies canbe used. For instance, proportional control only could be used.Alternatively, PI control could be used or full PID. In cases somecases, simple averaging could be used or other filtering techniquesincluding fuzzy logic and band-pass to reduce noise.

Still other embodiments can include additional types of sensors. In somecases, pressure sensors could be used under the insoles of an article toindicate when the user is standing. A motorized tensioning system can beprogrammed to automatically loosen the tension of the lace when the usermoves from the standing position to a sitting position. Such aconfiguration may be useful for older adults that may require lowtension when sitting to promote blood circulation but high tension forsafety when standing.

Still other embodiments could include additional tension sensingelements. In one embodiment, three point bend indicators could be usedin the lace to more accurately monitor the state of the tensioningsystem, including the lace. In other embodiments, various devices tomeasure deflection such as capacitive or inductive devices could beused. In some other embodiments, strain gauges could be used to measuretension induced strain in one or more components of a tensioning system.

In some embodiments, sensors such as gyroscopes and accelerometers couldbe incorporated into a tensioning system. In some embodiments, anaccelerometer and/or gyroscope could be used to detect sudden momentand/or position information that may be used as feedback for adjustinglace tension. These sensors could also be implemented to control periodsof sleep/awake to extend battery life. In some cases, for example,information from these sensors could be used to reduce tension in asystem when the user is inactive, and increase tension during periods ofgreater activity.

Some embodiments may use memory (for example onboard memory associatedwith a control unit) to store sensed data over time. This data may bestored for later upload and analysis. For example, one embodiment of anarticle of footwear may sense and store tension information over timethat can be later evaluated to look at trends in tightening.

It is also contemplated that some embodiments could incorporate pressuresensors to detect high pressure regions that may develop duringtightening. In some cases, the tension of a lace could be automaticallyreduced to avoid such high pressure regions. Additionally, in somecases, a system could prompt a user to alter them to these high pressureregions and suggest ways of avoiding them (by altering use or fit of thearticle).

It is contemplated that in some embodiments a user could be providedwith feedback through motor pulsing, which generates haptic feedback forthe user in the form of vibrations/sounds. Such provisions couldfacilitate operation of a tensioning system directly, or provide hapticfeedback for other systems in communication with a motorized tensioningdevice.

Control Methods

Various methods of automatically operating a motorized tensioning devicein response to various inputs can be used. For example, after initiallytightening a shoe, it is common for the lace tension to quickly declinein the first few minutes of use. Some embodiments of a tensioning systemmay include provisions for readjusting lace tension to the initialtension set by the user. In some embodiments, a control unit may beconfigured to monitor tension in those first minutes to then readjusttension to match original tension.

FIG. 39 is a schematic view of an exemplary process for automaticallyreadjusting lace tension to maintain the user desired tension over time.In some embodiments, some of the following steps could be accomplishedby a control unit 302 (see FIG. 31) associated with motorized tensioningdevice 160. In other embodiments, some of the following steps could beaccomplished by other components of a tensioning system. It will beunderstood that in other embodiments one or more of the following stepsmay be optional.

In step 502, control unit 302 may determine if a user has finishedtightening an article. In some cases, control unit 302 may determinethat a user has finished tightening a lace if no control commands (e.g.,an incremental tighten command) have been received after a predeterminedperiod of time. If control unit 302 determines that the user hasfinished tightening the article, control unit 302 proceeds to step 504.Otherwise, control unit 302 may wait until it has been determined thatthe user has finished tightening the article.

In step 504, control unit 302 may monitor tension of the tensioningsystem (e.g., tension of a lace) for a predetermined interval todetermine an initial tension. Methods for monitoring tension, includingcurrent sensors and other sensors have been previously discussed above.In some cases, control unit 302 may set the average measured tensionover the predetermined interval as the initial tension.

Next, in step 506, control unit 302 may determine if the tension of thetensioning system has decreased. If not, control unit 302 may wait andthen revaluate if the tension has decreased. Once it has been determinedthat the tension has decreased, control unit 302 may proceed to step508. In step 508, control unit 302 may automatically increase thetension of the tensioning system until the initial tension has beenachieved. In some embodiments, after step 508, control unit may wait andagain automatically evaluate the tension at step 506. In someembodiments, control unit 302 may be additionally configured toautomatically detect overtension and in response automatically decreasethe tension of the tensioning system until the initial tension has beenachieved. In some embodiments, control unit 302 may be configured toperform cyclic changes in tension, such as to enhance blood circulation.

In some embodiments, instead of only waiting a determined period oftime, as illustrated in FIG. 39 and described above, the reevaluation ofstep 506 may be triggered by sensor information. In one example,sensor-based triggering may replace the waiting, with sensor informationcausing reevaluation of tension to occur. In another example, waitingmay be performed as illustrated in FIG. 39, but with sensor informationpossibly causing the waiting to be terminated and triggeringreevaluation of tension. Sensors providing such information to controlunit 302 might include, but are not limited to, pressure sensors in shoeinsoles to detect standing and/or rate of motion, bend indicators,strain gauges, gyroscopes, and accelerometers. In some embodiments,instead of or in addition to maintaining an initial tension, the sensorinformation may be used to establish a new target tension. For example,pressure sensors could be used to measure contact pressures of a braceand automatically adjust used to avoid injury due to high pressure. Insome embodiments, control unit 302 may be configured to store sensorinformation obtained over a period of time to identify triggeringevents. Additionally, control unit 302 may be configured to upload orotherwise provide stored sensor information to a remote device. Uploadedsensor information may be reviewed and analyzed for purposes including,but not limited to, patient compliance for medical device use. Someembodiments may be configured to operate in two or more different modes.For example, some embodiments could operate in a “normal mode” and a“game mode” (or similarly, a “sports mode” or “active mode”). In thenormal mode, the electric motor would be powered down after tensioningin order to save battery life. In contrast, when the game mode isselected by a user, the tension of the system may be continuouslymonitored and adjusted for maximum performance though at the expense ofbattery life. By enabling a user to change between these two modes, auser can choose to optimize battery life or optimize performancedepending on the needs of the situation. In some embodiments, multipletarget tensions may be stored and returned to, for either of the “normalmode” or the “game mode,” such as configuring a target tension for sportand a substantially different tension for leisure. In some embodiments,control unit 302 may be configured to frequently, but not continuously,monitor and adjust tension, so as to further extend battery life whileachieving some of the benefit of a continuously monitored “game mode.”

FIG. 40 is a schematic view of an exemplary process for operating atensioning system in two different modes. In some embodiments, some ofthe following steps could be accomplished by a control unit 302 (seeFIG. 31) associated with motorized tensioning device 160. In otherembodiments, some of the following steps could be accomplished by othercomponents of a tensioning system. It will be understood that in otherembodiments one or more of the following steps may be optional.

In step 510, control unit 302 may receive the user selected mode. Thismay be determined by receiving a signal from a remote device, which mayprompt a user to select with a “normal mode” or a “game mode”. Next, instep 512, control unit 302 may determine if the user has finishedtightening the article. If not, control unit 302 waits until the userhas finished tightening the article. When the user has finishedtightening the article, control unit 302 proceeds to step 514. At step514, control unit 302 determines which mode has been selected from theinformation received during step 510. If the user has selected thenormal mode, control unit proceeds to step 516, where the motor ispowered down and the system awaits further instructions from the user(or other systems/sensors) to save battery power. If, however, the userhas selected the game mode at step 514, control unit 302 proceeds tostep 518. During step 518, control unit 302 may actively monitor thetension of the article and may automatically adjust the tension toachieve maximum performance.

As another example of a process for automatically controlling atensioning system, GPS feedback from a remote device could be used todetermine if a runner is on flat ground, climbing or descending. Thesystem could automatically adjust the tension of the laces in footwearautomatically, for example, by increasing tension in the laces duringdescent.

Although the exemplary methods described above and shown in FIGS. 39 and40 are directed to footwear, it will be understood that similar methodscould be used for automated operation of other kinds of articlesincluding tensioning systems. In particular, these methods could be usedwith any of the apparel previously discussed.

Alternative Embodiment of Motorized Tightening Device

FIG. 41 shows a schematic view of an alternative embodiment of amotorized tensioning device 900. For purposes of describing someinternal components, FIG. 43 illustrates a cross sectional view of somecomponents of motorized tensioning device 900. Motorized tensioningdevice 900 may include some similar provisions as the previousembodiments, for example a motor 902 and a gear reduction system 904that is driven by motor 902. Gear reduction system 904 as shown hereincludes 5 stages of spur gears. Other gear reductions that could beemployed include: cycloidal, harmonic, and planetary. In someembodiments, the motor 902 and gear reduction system 904 combination maybe sized to maximize the tradeoffs between current requirement, size,torque and speed. In the embodiment shown, the gear reduction isapproximately 600:1 with an output RPM of 30 and a peak current of 1.2amps.

The output of gear reduction system 904 may enter an incrementallyreleasable load holding mechanism 906, which is shown in FIG. 42. Thisload holding mechanism 906 comprises a ratcheting type mechanism, whichhelps hold any loads applied to spool 908 without potentially backdriving motor 902 and/or gear reduction system 904. The purpose is tohold the load without relying on the motor/gearbox to not back drive.Load holding mechanism 906 may hold load on spool 908 even while motor902 is de-energized. When a small amount of lace tension is desired tobe released, motor 902 unwinds and a sweeper element sweeps pawlelements 910 off internal teeth 912 allowing the output to unwind onetooth. This can be repeated as desired to precisely unwind the spool andcorrespondingly relax lace tension. This is important to allow the userto get to a precise fit. An exemplary load holding mechanism that may beused is disclosed in Soderberg et al., U.S. Patent ApplicationPublication Number 2010/0139057, now U.S. patent application Ser. No.12/623,362, filed Nov. 20, 2009 and titled “Reel Based Lacing System”,the entirety of which is hereby incorporated by reference.

Referring to FIGS. 41 and 43, the output of load holding mechanism 906in this embodiment is a male square drive 914. This drive element couldbe any number of sides or be an external spline. The male square drivemates with a female element 916 with sufficient clearance and of amaterial for low friction sliding along shaft 912 (see FIG. 43). Thefemale element 916 is driven by the male square drive 914. The oppositeend of female element 916 includes a face driving element 920. In theembodiment shown, this is a large number of triangular teeth which canengage or disengage from matching teeth on one flange of spool 908.These teeth could be from as few as one to more than eight. To encourageengagement the teeth may be back drafted from 5 to 60 degrees. In someembodiments, the teeth may be angled at approximately 45 degrees.

The center of female element 916 has a thread (not shown) which canengage threaded portion of shaft 912. When motor 902 is driven in onedirection element 916 moves axially as a result of the internal threadand engages the face teeth between itself and corresponding teeth onspool 908. Shaft 912, which is normally stationary, has a frictionalelement 922 to prevent rotation during axial travel and engagement. Whenengagement is complete and the face teeth are fully engaged, theexternal thread of shaft 912 will experience torque. Over a certaintorque level, motor 902 and gear reduction system 904 will overcome thetorsional friction element 922 and shaft 912 will turn. In theembodiment shown, frictional element 922 is an O-ring on shaft 912 thatis contained in a housing. The O-ring pressure can be adjusted via ascrew which can clamp down on the O-ring. In other embodiments, thistorsion friction could be accomplished by a number of means. Forexample, in another embodiment, torsional friction could be done as acoulomb frictional device such as an adjustable face clutch for instanceusing steel or brass against nylon or other brake pad materials andadjustable via an axial spring tensioner. In other embodiments,torsional friction could also be done electrically via a particle clutchor hydraulically via a rotary damper. In some embodiments, the number ofturns to reach disengagement can be coordinated if desired with thenumber of turns to go from full lace tension to no tension. That way,incremental release can be done anywhere in the range of lace that istensioned.

In the embodiment shown, rapid slack wind may be achieved via a constantforce spring (not shown) that is stored on a freewheeling spool 930 andrewound onto one end 930 of spool 908.

In some embodiments, the lace may exit and is tended through radiusedeyelets in a housing to prevent lace wear and increase lace fatiguelife.

In some embodiments, these exits may be located at least ½ of the spooldiameter away from the spool to help the lace more or less level windonto the spool to maximize capacity.

In some embodiments, a user initiated manual release element is alsoprovided should the user every find themselves in tightened shoes withno remaining battery life. Many approaches could be used to manuallydisengage the spool from the load holding and motor/gearbox mechanism.For instance a tapered blade (not shown) can be inserted between theteeth on spool 908 and element 916 to separate them via a spring elementallowing axial movement of spool 908 in the separation direction.

In addition, other example configurations of ratcheting mechanisms fordifferent embodiments of a motorized tensioning device can be understoodby studying devices 5300 and 5400 illustrated in FIGS. 53 and 54.

Alternate Tension and Release Mechanism

FIGS. 44 and 45 illustrate schematic views of an alternative tensioningand release mechanism that could be used with a motorized tighteningsystem. Another view of this mechanism is also shown in FIG. 47. Forpurposes of reference, this mechanism is shown in isolation from othercomponents of a tightening device. This mechanism can be used foraccomplishing tightening, load holding, incremental release and fullrelease.

In this design, a system of cams and latches are used. Referring toFIGS. 44 and 45, load holding mechanism 938 includes a final stageoutput gear 940 of a gear reduction system (not shown) which isconnected to a cylindrical plate 942 that has a single driving pawl 944near its center. In the tightening direction, the motor is continuallydriven and the pawl 944 drives via detents in an output ring 946 that isattached to the spool. This output ring 946 has internal detents 948that plate 942 drives and external female teeth 950 that engage anexternal load holding pawl 954. When the motor is stopped the externalload holding pawl 954 resists the spool torque. It can be seen thatplate 942 not only has the internal drive pawl 944 but also has camelements 945 on its periphery that periodically disengage the externalload holding pawl 954. When stopped and holding load the external pawlis engaged 954. Then the cylindrical plate 942 begins to back up for anincremental release. At first the output does not release. Then one ofcam elements 945 on plate 942 releases outside load holding pawl 954.When this happens, output ring 946 catches up to pawl 954 and next theload holding pawl 954 engages and the mechanism stops in an incrementalload holding position. In this way incremental release is accomplished.For this to operate a limit switch is employed to monitor plate 942 andstop in each incremental release position. In the embodiment shown thereare six stop positions or every 60 degrees of rotation. This number canvary based on space requirements and the incremental lace releaseresolution desired. There could be as few as 1 stop per revolution andas many as 12, for example.

For full release, mechanism 938 must be stopped with both the internaland external pawl released at the same time. There is one more releasingpawl 960 required to accomplish this. In the figure, pawl 960 has threepositions. Fully retracted, actuator extended, and releasing camextended. After tensioning, pawl 960 is fully retracted, as incrementalreleases are actuated the internal pawl 944 will likely pass thisexternal pawl 960 and set it to the full release position. So when afull release is commanded, the internal pawl 944 will move into aposition where both internal and external pawls are lifted and the usercan freely extract lace and take off the article while only encounteringminimal resistance which is provided by the slack take up mechanism.

Manual Release System

FIG. 46 illustrates an embodiment of an alternative manual releasesystem from the system described above. Referring to FIG. 46, article1000 may be similar to previous embodiments and can include a tensioningsystem 1002 with a lace 1004 and a motorized tensioning device 1006. Inthis embodiment, a portion of lace 1004 is equipped with a manualrelease mechanism 1010. In the embodiment shown here, manual releasemechanism 1010 includes corresponding fasteners 1012 that can bemanually disconnected to relieve lace tension. In some cases, fasteners1012 comprise a screw together clasp. However, other embodiments couldutilized any other fastening provisions including a snap fit connector,a hook and receiver type connector, or any other kinds of fastenersknown in the art.

Medical Braces

Embodiments of a tensioning system, including a motorized tighteningdevice may be incorporated into medical braces or other medicalprotective wear. Examples of different types of braces include, but arenot limited to: wrist braces, arm braces, leg braces, knee braces, anklebraces, as well as any other kinds of braces and protective wear. In oneembodiment, a motorized tightening device may be incorporated into thelacing system for a medial brace disclosed in Nickel et al., U.S. PatentApplication Publication Number 2012/0004587, now U.S. patent applicationSer. No. 13/174,533, filed Jun. 30, 2011 and titled “Braces Using LacingSystems” (the “Braces application”), the entirety of which is herebyincorporated by reference. For example, a motorized tightening device,including various embodiments described here, could be incorporated intoa wrist brace or ankle brace, which are described with various manualtightening systems in the Braces application. A motorized tighteningdevice could also be incorporated into the closure system of theorthopedic braces and protective wear disclosed in Hammerslag et al.,U.S. Patent Application Publication Number 2008/0066272, now U.S. patentapplication Ser. No. 11/854,522, filed Sep. 12, 2007 and titled “ClosureSystem for Braces, Protective Wear and Similar Articles” (the“Protective Wear application”), the entirety of which is herebyincorporated by reference. For example, a motorized tightening devicecould be incorporated into any of the orthopedic devices (such as kneebraces and leg braces) that are described with various manual tighteningsystems in the Protective Wear application. Various exemplary types ofbraces incorporating tensioning systems with motorized tighteningdevices are shown in FIGS. 48-52.

As with footwear and other articles, using a motorized tightening devicefor a lacing or tensioning system on a brace may provide benefits overmanual tightening methods. For example, having a repeatable (measurable)closure may allow a doctor to prescribe a particular tension setting forthe brace, allowing the tensioning to act as a repeatable “dosage”.Moreover, repeatable closure may improve ease of use allowing a user toput on the brace, press a button and have the brace automatically adjustto the predetermined tension.

It is contemplated that in embodiments including medical braces the“dosing” of the brace tension could be digitally transmitted to a doctorand/or received digitally (at the device) by a doctor. This allows adoctor to efficiently monitor tension, especially as changes may occurdue to stretch of the brace, changes in body size, as well as possiblyother factors. This also may allow a doctor to tighten the brace (orrecommend a tensioning level to the patient) according to a dose leveland keep it there over time and as changes occur.

Using a motorized tensioning device may remove dexterity issues that mayoccur with other tensioning technologies (pulling straps, Velcro, etc. .. . ). Such a design could improve the use of braces for physicallyimpaired, or injured individuals who may otherwise have a hard timeputting on and adjusting their braces. Using the designs proposed here,a brace could be tightened via a push button or remote interface. Anexemplary remote interface 5001 for tightening a knee brace 5002 isshown in FIG. 50.

In some embodiments, a brace incorporating a motorized tensioning devicecan be configured to constantly measure internal system tension and thenreact to maintain a pre-determined tension level. This may help reduceover-tensioning of the device. This may also help in automaticallyadjusting the brace to a limb as it shrinks from swelling reductionand/or atrophy. In some embodiments, the brace could adjust to provideadditional support when/if the brace detects unusually high tensions dueto a user falling on the injured limb.

Still additional elements can be added to a brace to aid in reactivity.For example, in some embodiments, a member within the brace that is ableto shorten and stiffen at either prescribed times, or when additionalsupport is needed. Such a feature could be accomplished using themotorized tensioning technology as well as possibly other provisions.

A motorized tension device used to tension a brace can also facilitateproactive adjustment of the brace. For example, motorized compressioncan be used for proactively adjusting compression of a bracing product.In one example, a motorized tensioning device may automatically adjustthe tension in a brace at timed intervals, which can encourage bloodflow and promote healing. As another example, a motorized tensioningdevice may automatically adjust tension to correspond with the positionof a patient's body or activity. For instance, one level of tensioningcould be provided for sitting, a second level of tensioning could beprovided for standing and a third level of tensioning could be providedfor activities such as walking, running or other ambulatory activities,sitting require one level of protection/support/tension

An additional provision that could be used with a brace incorporating amotorized tensioning device for adjusting tensioning in a lace or othertensioning member include a spring based opening. In particular, someembodiments may include a spring between eyestays to keep the brace openwhen the brace is not in tension. This may make it easier to put thebrace on and/or remove the brace. Additionally, this spring basedopening may reduce lace tangling issues by proactively keeping lacepulled out of the tensioning device once tension has been released.

Various charging strategies could be employed for a medical braceincluding inductive charging, plug in charging as well as the use ofremovable batteries. An example of an inductive charging configuration5100 for a brace is shown in FIG. 51.

Examples of user interfaces include a turn dial for tightening orloosening the tension. An exemplary configuration of a back brace 4901with a motorized tightening device 4902 that uses a turn dial type usercontrol 4903 is shown in FIG. 49. Another possible interface includes aconductive panel where a user moves their finger up or down to adjusttensioning. FIG. 52 shows one such interface for motorized tighteningdevice 5200. Still another interface could be a push button interface.

Methods of digitally tracking tensioning data measured by one or moresensors could be used in some embodiments. The average tension of thedevice could also be tracked, to measure swelling, atrophy, etc. Inaddition, in some cases, the number of times the brace is put on andtaken off can be tracked. Time of use and the level of patientcompliance could also be tracked.

Data collection could be facilitated by various technologies includingUSB devices, data cords and blue tooth communication technologies.Moreover, the data collected can be transmitted through a variety oftechnologies to either a central database for evaluation, and/ordirectly to a physician to allow them to monitor the progress of apatient. FIG. 48 shows exemplary communication modes between atightening system 4801 and a computer 4802, including a Bluetoothconnection 4803 and a USB connection 4804.

While various embodiments of the embodiments have been described, thedescription is intended to be exemplary, rather than limiting and itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the embodiments. Accordingly, the embodiments are not to berestricted except in light of the attached claims and their equivalents.Also, various modifications and changes may be made within the scope ofthe attached claims.

The invention claimed is:
 1. An article of footwear, comprising: amotorized tensioning system that is configured to adjust a tension levelof the article of footwear from a first tension level to a secondtension level, wherein the first tension level is greater than thesecond tension level, wherein the motorized tensioning system comprises:a motor; and a limit switch assembly, operatively coupled to the motor,configured to measure current levels associated with the operation ofthe motor, wherein there is a first current level associated withoperating the motor when the article of footwear is tensioned at thefirst tension level, wherein there is a second current level associatedwith operating the motor when the article of footwear is tensioned atthe second tension level; wherein the first current level is differentfrom the second current level.
 2. The article of footwear of claim 1,further comprising: a control device, the control device comprising afirst button and a second button; the control device being configured toprovide manual control of the motorized tensioning system; and whereininteraction with the first button initiates an increase in the tensionlevel of the article of footwear.
 3. The article of footwear of claim 2,wherein interaction with the second button initiates a decrease in thetension level of the article of footwear.
 4. The article of footwear ofclaim 2, wherein the increase in the tension level of the article offootwear occurs while the motor operates in a forward direction.
 5. Thearticle of footwear of claim 4, wherein the decrease in the tensionlevel of the article of footwear occurs while the motor operates in areverse direction with an operation of the motor in a reverse direction.6. The article of footwear of claim 1, wherein an increase in a currentlevel associated with operating the motor corresponds with an increasein the tension level of the article of footwear.
 7. The article offootwear of claim 1, wherein the first current level is greater than thesecond current level.
 8. An article of footwear, comprising: anautomated tensioning system that is configured to adjust a level oftension associated with the article of footwear, wherein the motorizedtensioning system comprises: a motor, wherein the motor operates in afirst direction and a second direction, wherein the motor operates inthe first direction as the level of tension is increased, wherein themotor operates in the second direction as the level of tension isdecreased; and a limit switch assembly configured to measure currentlevels associated with the operation of the motor, wherein the automatedtensioning system determines the level of tension of the article offootwear based on the current levels following operation of the motor inthe second direction.
 9. The article of footwear of claim 8, wherein themotor is configured to cease operating upon registration of a safetytimeout by the automated tensioning system.
 10. The article of footwearof claim 8, wherein operation of the motor in the first direction iscorrelated with an increase in the current level associated with themotor.
 11. The article of footwear of claim 8, wherein operation of themotor in the second direction is correlated with a decrease in thecurrent level associated with the motor.
 12. The article of footwear ofclaim 8, wherein the automated tensioning system is configured to save apreset level of tension, and wherein the automated tensioning system isconfigured to operate the motor in order to adjust the level of tensionof the article of footwear to the preset level of tension.
 13. Thearticle of footwear of claim 12, wherein the preset level of tension issaved by storing information regarding the current level associated withthe preset level of tension.
 14. The article of footwear of claim 8,wherein the automated tensioning system determines the level of tensionof the article of footwear by measuring the current level within 0.001and 10 seconds of the motor operation in the second direction.
 15. Anarticle of footwear, comprising: a fastening mechanism associated withtwo or more tension levels; an automated tensioning system configured toadjust the tension level of the fastening mechanism from a first tensionlevel to a second tension level, wherein the first tension level isdifferent from the second tension level, wherein the automatedtensioning system comprises: a motor and a limit switch assemblyconfigured to measure current levels associated with the operation ofthe motor, the first and second tension levels being determined based onthe current levels; the automated tensioning system being configured tostore the first tension level; and the automated tensioning system beingconfigured to operate the motor such that the tension level of thefastening mechanism returns to the first tension level automatically.16. The article of footwear of claim 15, further including a sensor,wherein activation of the sensor initiates a command to the automatedtensioning system to return to the first tension level.
 17. The articleof footwear of claim 16, wherein the sensor is a force sensitiveresistor disposed in a heel region of the article of footwear.
 18. Thearticle of footwear of claim 15, further including a control device,wherein interaction with the control device can initiate a command tothe automated tensioning system to return to the first tension level.19. The article of footwear of claim 15, wherein a measurement of acurrent that is associated with operation of the motor is used todetermine the tension level of the article.
 20. The article of footwearof claim 15, wherein the first tension level is stored by measurementand storage of a current level that is associated with an operation ofthe motor that adjusts the tension level of the article of footwear tothe first tension level.
 21. A method of automatically adjusting tensionin an article of footwear, comprising: adjusting a tension level of thearticle of footwear to a first tension level; measuring, with a limitswitch assembly, a first current level associated with the operation ofa motor during the adjustment to the first tension level; storing thefirst current level in memory; adjusting the tension level of thearticle of footwear to a second tension level that is different from thefirst tension level; and returning the tension level of the article offootwear to the first tension level.
 22. The method of automaticallyadjusting tension in an article of footwear of claim 21, wherein thestep of returning the tension level of the article of footwear to thefirst tension level occurs in response to an input being registered by asensor.
 23. The method of automatically adjusting tension in an articleof footwear of claim 21, wherein the step of returning the tension levelof the article of footwear to the first tension level occurs in responseto registration of an input into a control device.